Method of forming bonds



A ril 28, 1936. R, TEMPLE, JR

METHOD OF FORMING BONDS Filed April 28, 1933 5 Sheets-Sheet l ROBERT TEMPLE JR.

[1V Vii V TOR. B Y [M A TTORNEY April 23, 1935- R. TEMPLE, JR

METHOD OF FORMING BONDS Filed April 28, 1935 5 Sheets-Sheet 2 ROBERT TEMPLE JR.

INVENTOR.

ATTORNEY April 28, 1936. R; TEMPLE, JR I 2,038,913

METHOD .OF FORMING BONDS Filed April 28, 1953 5 Sheets-Sheet 3 ROBERT PLE JR.

VENTOR.

BY ATTORNEY April 28, 1936. R TEMPLE, JR 2,038,913

METHOD OF FORMING BONDS Filed April 28, 1955 5 Sheets-Sheet 4 150- mum 15g 138 140 I 139 Z 148 143 g 136 1 1% ROBERT TEMPLE JR.

ATTORNEY Apxrfifi 28, 1%35. R T JR 2,038,913

METHOD OF FORMING BONDS Filed April 28, 1955 .5 Sheets-Sheet 5 HIV ROBERT TEMPLE JR.

INVENTOR. By Z fadz,

A TTORNEY 1 Apr. a, recs 7 v v 21.0 9 1 lTED STATES PATENT OFFICE METHOD OF FORMING BONDS Robert Temple, Jr.,' Brooklyn, N. Y. Application April 28, 1933, Serial No. 668,371 9 Claims. (01. 29-148) This invention relates to a method of forming place, and explosively actuated means for driving bonds by explosively actuated means and relates the projectile into the bond, thereby causing the more specifically to a method of joining male and latter to expand and amx it to the rail or other female members together which consists generally structure with a perfect contact. 5 in driving an element into one or both of the The second embodiment illustrated in the draw- 6 members under the impulse created by a confined ings is an apparatus for securing a connector to explosive charge. The invention has an espea main cable in tap-off work. In this instance the cially important use in forming electrical connecconnector comprises a structure, made preferably 'tions. of copper and. having two or more. longitudinal 10 Considerable diiliculty is experienced in securapertures therein, usually parallel with each 10 ing, at low cost, a perfect connection between two other. The main cable is out where it is to be conductors of electricity, whether the .conductors tapped and the two end portions thereof are into be joined include two wires, or a wire and a serted into one of the apertures wherein they surface, or otherwise. Heretofore the best remeet substantially midway. Aretractable clampis sults have been obtained from welding, brazing, or ing structure is then secured to the connector and soldering, it being found that mere pressure bea. projectile fired thereinto. Thus, the projectile tween the two portions is insufiicient to give a expands the cable and assures a contact of high good connection. conductivity. The tap-01f wires may then be in- One of the electrical connection problems sorted into the other aperture and a projectile which frequently require welding, with its atdriven thereinto in the same fashion. In the 20 tendant expense and inconvenience, is in securing event that the tap-off wire is of smaller diameter bonds to rails. In recent years, however, a hythan the aperture a copper bushing may be indraulic press has been employed at less expense serted in the aperture. Likewise, if a number of than welding. A hole is drilled in the rail and a tap-off wires are desired a second connector is emg5 copper bond or terminal which carries the connecployed, having two or more apertures therein. 5 tor wire, is inserted in the hole, the bond having The invention also contemplates the provision a flange or headed portion at one end to prevent of a method of bonding by explosively actuated it passing completely through the aperture. The means wherein no recoil develops as a result of the press isthen employed to compress the bond withfiring. This is accomplished by confining and in the aperture and a fair result is obtained. sealing the explosive charge in a manner some- 30 One of the objects of the present invention is h t similar t t t shown in United s t the provision of an improved method of forcing t r Patent Nos. 1,365,869 and 1,365,890 granted a projectile-like member into a solid bond, thereby t my father, Robert Temple, expanding i to point Where a Perfect Connec- A further object of the invention is the provition will be obtained. sion of a novel method for the securing of a bond 35 In its broader aspect, however, the instant int m t a rail which includes inserting th vention contemplates the provision oi a method of n terminal t an aperture in t rail, driving rin a male n f m m m together by a projectile into the bond with suchavelocltyasto driving a projectile and/or the make the expansion great enough to secure a flemale member under hlgh Vekmty- The practically perfect contact, explosively actuated Jecme may e ,Only the male member means being employed for the driving power, the itrllietigeiygee xrrlgaengreixiggi sgii eitaxiaals y gegrzrg ti fi result being accomplished wlthoutnoise, recoil members, the perfect connection being obtained zgggfi giggggg 5 32i; wmch wouldbeda'ngeras i of expanslm' In any event the With the above indicated objects in view, the penetrating f causes the members to invention resides in certain novel constructions pand and by so doing amxes them together under and combinations and arrangements of parts,

reat ressure throu h. the 1' teral ex ansion of t ma te1'ia1s g d p clearly described in the following specification .70 Of the two of many embodiments of the appaand fully illustrated in h a f p y ratus for carrying out the method which are il1usingS, w h a e S embodlments 0 t trated in the drawings, one is a device for penevention as at present preferred.

trating rail and other bonds of the kind above re- In the drawings: ferred to, the device including a retractable Fig. l is a front elevation of the first embodiclamping structure which secures the bond in ment of the invention, partially in section, the 55 clamping structure being shown in the safety or non-firing position.

Fig. 2 is a broken vertical section of the embodiment, the detonating portions being shown in firing position.

Fig. 3 is an end elevation of the apparatus.

Fig. 4 is a broken top plan view, partially in section.

Fig. 5 is a section on line 5-5 of Fig. 1, the view showing the pinion removed.

Fig. 6 is a perspective-view of the firing pin actuator.

Fig. 7 is a perspective view of the detonater block.

Fig. 8 is a side elevation of the screw which assembles the projectile unit.

Fig. 9 is a broken horizontal transverse section taken through a rail and bond secured therein, the view showing the position of the pro jectile.

Fig. 10 is similar to Fig. 9 but shows the position of the projectile when fired from the opposite end of the bond.

Fig. 11 shows a modification in the construction of the bond when used for conducting low amperage currents.

Fig. 12 shows the same bond in place.

Fig. 13 is a side elevation, partially in section, of the second embodiment of the invention.

Fig. 14 is a front elevation thereof.

Fig. 15 is a front elevation of the striking tool for the firing pin.

Figs. 16, 17 and 18 are perspective views of reducing bushings employed in the device.

Fig. 19 is a modified connector unit.

Fig. 20 is a broken perspective view of the detonator block.

The first embodiment of the apparatus for carrying out the method is illustrated in Figs. 1 to 8 inclusive, and comprises a substantially U shaped, retractable clamping structure 5. This structure includes a. downwardly extending shaped female member 6 and a downwardly extending male member I which carries the ereplosive means.

The female member 6 is shaped to provide an inwardly extending portion 8 at its lower end to engage the head portion 9 of a conventional solid copper rail bond or terminal id which. is placed within a newly drilled aperture ii in a rail [2. These bonds are of standard construction and are secured at each end of a connector wire (not shown).

The annular edges l3 of the face of the portion 8 are preferably bevelled. A centrally disposed aperture l5 extends inwardly from the face.

The horizontal portion l6 of the female member 6 is provided with a longitudinal aperture l1 therein. Within this aperture the horizontal portion l8 of the male member passes, said portion having a plurality of vertically disposed teeth. l9 which function as a rack, said teeth being engaged by a pinion 20.

The pinion 2i! is mounted for pivoted movement on the horizontal portion 1 E; of the member 6 in the following manner. A pair of upper and lower lug or pivot supporting portions 2?. and 23, respectively, are integral with said horizontal portion I6, said portion having aligned vertical apertures 24 and 25 therein. A shaft 26 having a. circular handle 21 is carried within said aperture, said shaft having a flange portion 28 which engages the upper surface of the upper lug 22. immediately below the flange is a portion 29 of the shaft which fits within the aperture 24 in die in one direction the male member 1 moves outwardly to give sufficient clearance at the lower end of the structure to enable it to pass over the head of the rail. By turning it in the opposite direction the members move together to the position shown in Fig. 2. When this position is reached the pinion is secured against rotation by means of a dog 36 pivotally mounted at 31 in lugs 38 and 39, also integral with the horizontal portion It, the dog being urged outwardly by means of a spring 40, all as clearly illustrated in Figs. 4 and 5.

The male member 1 is secured against rotation within the female member G'by means of a key 42 secured in a recess in the inner portion of the aperture in the female member, a screw 43 securing said key. The key passes in a longitudinal recess 44 in the male portion i8, all as shown in Figs. 4 and 5. g

The following explosive means for driving the projectile into the bond are provided. The vertical portion 48 of the male member 1 is provided, at its lower end, with a circular aperture 41 extending inwardly substantially two thirds of its thickness. Within this aperture a cylindrical sleeve 48 is positioned and is adapted for longitudinal movement. One end of the sleeve is closed and is provided with a threaded aperture 49 in which an externally threaded breeching element 58 is positioned. The breeching element is longer than the thickness of the end portion of the sleeve 48 and an elongated cylindrical barrel 5| is carried on the outer end of said breeching element, the inner end of the barrel being threaded to provide for easy removal. The external diameter of the-barrel is of such size as to fit snugly within the projectile and explosive element which will' 7 now be described.

The projectile, which is designated as 60 is of a tapered construction, and is preferably made from tempered steel, or the like. The opposite end of the projectile is provided with a threaded aperture iii which carries a threaded screw 62. Inasmuch as no movement of the projectile can take place until the explosive gases have built up suiiicient pressure to break the screw, the screw is provided with an annular recess 63 to facilitate the breaking. Adjoining the rear end of the projectile is a cup 64 closely fitting the base of the barrel, said cup having a central threaded aperture through which the screw 62 passes, thereby securing the cup, the projectile and the screw together. A cylindrical detonator block 65, having a threaded aperture 66, is carried at the opposite end of the screw and is of an enlarged diameter to closely fit the enlarged portion of the aperture in the barrel and rests against the shoulder B. A detonator cap 61 is positioned in a recess in the block, said block also having a longitudinal slope 68 through which the flash from the cap may travel into the chamber provided by the cup, which chamber is filled with a suitable charge of powder 69.

Thus, when the detonation takes place, the ini- I tial movement of the projectile 60 and the cup 6-1 is retarded until suificient pressure is built up to break the screw 62. When this occurs the projectile moves forward and into the bond, the cup being stopped when it strikes the end of the bond. By virtue of the fact that the cup closely fits the bore of the barrel, the explosive gases are not immediately released after the explosion, this fact being responsible for the lack of any recoil in the apparatus.

The following means are employed toactuate the firing pin which is designated as I0, the pin being adapted to pass through an aperture in the breeching element. The pin is integral with a firing rod I2 having a curved headed portion I3 and mounted in an aperture '14. The firing rod is caused to move forward by means of a firing pin actuator I5 illustrated in detail in Fig. 6. The

actuator includes an ofiset portion 16 at the upper end thereof, a spring engaging ofiset portion 11 substantially midway, and a diagonal portion I8 at the lower end which engages the head I3 of the firing rod 12. The actuator is mounted for longitudinal movement within a slot 80 in the outer surface of the vertical portion 46 of the male member and is secured against removal by means ofa plate 8I held thereon by screws 82. The actuator is urged upwards by means of a spring 83 positioned within a recess 84 in the slot 80, the upper end of the spring engaging the ofiset portion 71.

The actuator is moved downwards by means of a removable pin 85 which is mounted in an aperture 86 in the portion 46, the pin engaging the offset portion I6 of the actuator.

In order to prevent accidental discharge of the apparatus the following safety means are provided. An aperture 88 in the breeching element 50 receives a coil spring 89, the opposite end of the spring engaging the rear wall of the aperture 41 at the lower end of the male member. The spring normally urges the breeching 50 and the sleeve outwardly, as shown in Fig. 1, the outward movement thereof being limited by means of a set screw (not shown). Rotation of the bushing is prevented by means of a key 9I,'secured at the lower side of the aperture 41 by means of a screw 92, the key extending into a slot 93 in the bushing.

When in this outward position, as shown in Fig. l, the firing pin 78 does not lie adjacent to the detonating cap 6?, thereby preventing accidental discharge. When, however, the handle 2'! is revolved further, thereby drawing the male member I inwardly to the position indicated in Fig. 2, the firing pin is adjacent to the cap and when the firing rod actuator is moved downwards by the pin 85 the charge is set oif and the projectile driven into the bond.

Fig. 9 shows the position of the projectile 60 after it has penetrated the bond I0. The firm support or" the bond duringthe penetration prevents any appreciable amount of the copper from passing out, as shown.

In Fig. 10 the projectile B0 is shown as being fired through the head of the bond which is almost as satisfactory except that some of the copcai portions I 0| and per escapes unless it is very firmly supported at both ends.

Fig. 11 shows a modified form of bond for use in low amperage work wherein a much smaller bond may be used than in high amperage work. This bond is particularly adapted for signal connectors whichare secured to the rails.

In this instance an aperture 94 is drilled something less than one-half an inch into the head of the rail I2 and the bond 05 is inserted thereinto. The projectile (not shown) is tapered at a greater angle so that after it is fired it may be readily removed, thus leaving the bond secured with the aperture as shown in Fig. 12.

The second embodiment of the apparatus, il-

lustrated ln-Figs. '13 to inclusive, is an exsion is obtained and aperfect electrical connection results.

In a previous application, serial No. 557,857 I described a press capable of developing tremendous pressure for cable splicing work. In this instancethe two ends of the cable to be connected are placed in opposite ends of a copper sleeve which is compressed in a plurality'of places under twenty to thirty tons pressure.

The second embodiment of the present invention is designed largely for tap-ofi work rather than cable splicing. It contemplates the use of a copper connector of the: type illustrated in Figs. 13 and '14. The connector, which is designated as I00 is preferably cast or pressed from copper and includes two or more integral cylindri- I02 having longitudinal ap-' ertures I03 and I04 parallel with each other. For convenience in supporting the connector during thepenetrating operation a concave depressed portion I05 is provided on each side. Also to aid in placing the ends of the cable within the apertures the proper distance the central wall I06 is provided in each aperture.

When a main cable, which is usually of the size of the apertures I03 and I04, is to be tapped, the cable is cut in.v the proper position and the ends inserted within one ofthe apertures and a projectile driven thereinto as hereinafter described. The driving of the projectile causes the cable to expand laterally against the walls of the aperture and give a perfect contact. The other aperture may then be employed to receive the auxiliary tap-off wire. In the event that the latter is smaller than the aperture. reducing apertures III, the connector being adapted to be inserted within the apparatus as hereinafter described.

The driving device in this instance includes an elongated barrel 20 having an aperture I2i extending therethrough. The lower end of the aperture is slightly tapered as shown at I22 to aid in the removal of the cup portion of the projectile, hereinafterdescribed, after the detonation. The connector I00 rests in a C shaped connector supporting element, I23 having a concave lower portion I24 to receive the connector, and a threaded aperture I25 at its upper end to receive the threaded portion I26 of the barrel. A threaded bushing I21 at the lower end of the barrel is secured against rotation by a set screw I28, the bushing preventing removal of the con-- 'nector supporting element. When it is desired to insert the connector the barrel is revolved by turning a handle I29 which is keyed to the barrel,

' and after the connector is in place the handle is revolved in the opposite direction until the lower end of the barrel engages the connector firmly, as shown in Figs. 13 and 14.

Fig. 13 shows the new improvement in the projectile unit which provides means for more efi'ective sealing of the explosive gases in their chamber beforethe initial movement of the cup and the projectile takes place.

The projectile unit includes a tapered projectile I 34 having a threaded aperture I35 at its rear end. A threaded screw I36 is held in this aperture, the screw also supporting the tapered cup I31. The opposite end of the screw is secured to the detonator block I38 similar to that illustrated in the first embodiment, the block having a threaded aperture I39 to receive the screw and a slot I40 to conduct the flash. Thus, the projectile unit is assembled into one piece which separates with suificient pressure built up to break the screw.

The detonator block in this instance is formed with a reduced portion I4I, the shoulder I42 formed thereby engaging the shoulder I43 formed by an enlarged portion I44 at the upper end of the aperture I2I in the barrel.

The reduced portion MI is hollow forming a circular chamber indicated at I45, the lower edge I46 thereof engaging a shoulder I47 in the barrel, thus giving the detonator block two points of support. The upper edge I48 of the cup I31, when assembled, as shown in Fig. 13, extends into the chamber I45, closely fitting therein to prevent the escape of gases, until suflicient pressure is built up to break the screw.

The detonator block is held in place by means of a screw cap I49 having a central aperture I50 to receive the firing pin I5I. The firing pin is secured against removal by a set screw I52 which engages a slot I53 in the firing pin.

In this type of tool it is desired to provide separate and unattached means for striking the firing pin which in this instance is a hammer I54 having a ball head I55.

The hcreinbefore described construction admits of considerable modification without departing from the invention; therefore, it is the wish not to be limited to the precise arrangements shown and described, which are as aforesaid, by way of illustration merely. In other words the scope of protection contemplated is to be taken solely from the appended claims, interpreted as broadly as is consistent with the prior art.

\Vhat I claim is:

l. The method of securing a substantially solid male member and a female member together which consists in first inserting the male member within the female member, and then driving a within the female member and then driving a tapered projectile into the male member under the impulse created by a confined explosive charge, the initial movement of the projectile being delayed until the explosive gases have built up a predetermined maximum pressure. I

3. The method of securing a plurality of substantially solid male members within a female member, which consists in inserting the male members within the female member, and then driving a tapered projectile into the female member under the impulse created by a cdnflned explosive charge, the initial movement of the projectile being delayed until the explosive gases have built up a predetermined maximum pressure.

4. The method of securing a substantially solid headed bond terminal to a rail which consists in forming an aperture in the web of the rail of substantially'the same diameter as the diameter of the terminal, firmly supporting the terminal in the aperture by means of a releasable clamping structure, driving a tapered projectile into said terminal at ahigh velocity under the impulse created by a confined explosive charge, the initial movement of the projectile being retarded until the explosive gases have built up a predetermined maximum pressure.

5. The method of securing a substantially solid bond terminal to a. rail which consists in forming an aperture in the rail of substantially the same diameter as the diameter of the terminal, driving a projectile into said terminal at a high velocity under the impulse created by an explosive charge, the initial movement of the projectile being delayed until the explosive gases have built up a. maximum pressure.

6. The method of securing a substantially solid member to a rail or the like which consists in forming an aperture in the rail of substantially the same diameter as the diameter 01' the terminal, supporting the member within the aperture, driving a projectile into said member at a. high velocity under the impulse created by a confined explosive charge, the initial movement of the projectile being retarded until the explosive gases have built up a maximum pressure, and then removing the projectile from said member.

'7. The method of securing a substantially solid bond terminal to a rail which consists in forming an aperture in the head of the rail of substantially the same diameter as the diameter of the terminal, supporting the terminal in the aperture, driving a tapered projectile into said terminal at a high velocity under the impulse created by a confined explosive charge, the initial movement of the projectile being retarded until the explosive gases have built up a maximum pressure, and then removing the projectile from said terminal.

8. The method of joining the terminals of wires, which consists in inserting said terminals within a coupling having an aperture of substantially the same size as the diameter of the wires, then driving a tapered projectile into said coupling and the wires at a high velocity under the impulse 2,088,918 created by a confined explosive charge, the initial movement of the projectile being delayed until the explosive gases have built up a predetermined maximum pressure.

9. The method of tapping an electrical conductor which consists in severing the conductor at the desired point, then inserting the terminals of the severed conductor within a connector having a plurality of longitudinal bores therein, driv- 10 ing a plurality of tapered projectiles into the con- 

